Device and method for assembling mold for forming plastic lens

ABSTRACT

A device ( 20 ) for assembling a plastic-lens-forming casting mold includes a gasket clamping mechanism ( 22 ) which clamps a gasket ( 2 ) from its axial direction, a first mold push-in mechanism ( 23 ) which pushes in an upper mold ( 3 ) fitted in an upper open end of the gasket ( 2 ), and a second mold push-in mechanism ( 24 ) which pushes in a lower mold ( 4 ) fitted in a lower open end of the gasket ( 2 ). The gasket clamping mechanism ( 22 ) clamps the gasket ( 2 ) from the axial direction by a gasket-pressing ring ( 34 ) and lower mold ring ( 35 ). The first mold push-in mechanism ( 23 ) pushes the upper mold ( 3 ) into the gasket ( 2 ) by a gasket push-in member ( 58 ). The second mold push-in mechanism ( 24 ) includes a plurality of push pins ( 68 ) and pushes up the lower mold ( 4 ) to push it into the gasket ( 2 ).

BACKGROUND OF THE INVENTION

The present invention relates to a device and method for assembling aplastic-lens-forming casting mold which is used when forming a plasticlens by casting polymerization.

Casting polymerization is known as a method of forming a plastic lens. Aplastic-lens-forming casting mold used for casting polymerizationusually includes a pair of molds which form the optical surfaces (convexsurface and concave surface) of a plastic lens and a cylindrical castinggasket (to be abbreviated as a gasket hereinafter) in which the moldsare fitted at a predetermined gap from each other and which defines theouter diameter of the lens. When forming the lens, first, the pair ofmolds are incorporated in the gasket to build the casting mold.Subsequently, a liquid monomer fills the internal space (cavity) of thecasting mold. The casting mold is loaded in a heating furnace, and themonomer is heated and polymerized at a predetermined temperature for apredetermined period of time to harden. The casting mold is extractedfrom the heating furnace and released, so that a monomer molded product(lens) in the casting mold is released from the mold and extracted (see,e.g., Japanese Patent Publication No. 6-98631, Japanese Utility ModelLaid-Open No. 55-134224, Japanese Utility Model Publication No. 6-39951,U.S. Pat. No. 4,251,474, Japanese Patent Laid-Open No. 4-232706, and“Spectacles” Jul. 1, 1987, p.p. 79-81, Kabushiki Kaisha Medical AoiShuppan).

The plastic lens manufacturing method described in Japanese PatentPublication No. 6-98631 includes a cylindrical gasket having a ring-likeprojection formed on its inner surface in the circumferential direction,and upper and lower molds to be incorporated in the gasket. The uppermold forms the front surface (convex optical surface) of a lens to beformed. When the upper mold is pushed into the gasket from above, itsperipheral portion abuts against the projection, so that the upper moldis positioned. The lower mold forms the rear surface (concave opticalsurface) of the lens, and is pushed into the gasket from below by apushing die. The pushing die which pushes the lower mold into the gasketincludes a disk-like base and a cylindrical step projecting from thebase. When the lower mold is placed on the pushing die, the step isinserted in the gasket, and the base abuts against the lower end face ofthe gasket, to define the push-in amount of the lower mold into thegasket.

The plastic-lens-forming casting mold described in Japanese UtilityModel Publication No. 6-39951 includes a gasket made of a syntheticresin into an elastic cylindrical body, and a pair of molds to beincorporated in the gasket. The gasket has a ring-like projectionprojecting from its inner surface. The projection positions the pair ofmolds.

The plastic-lens-forming casting mold described in each of JapaneseUtility Model Laid-Open No. 55-134224, Japanese Utility ModelPublication No. 6-39951, and U.S. Pat. No. 4,251,474 includes a gaskethaving a ring-like ridge projecting from its inner wall surface in thecircumferential direction, and a pair of molds. The pair of molds arefitted in the gasket and positioned by the ridge.

The plastic-lens-forming casting mold described in Japanese PatentLaid-Open No. 4-232706 includes a gasket and a pair of molds to beincorporated in the gasket. The gasket has a ring-like holding bandformed on its inner wall surface, and a plurality of holding portionsprojecting at appropriate gaps in a circumferential direction. When onemold is incorporated in the gasket, it is positioned by the ring-likeholding band. When the other mold is incorporated in the gasket, it ispositioned by the plurality of holding portions.

The plastic-lens-forming method described in “Spectacles”, KabushikiKaisha Medical Aoi Shuppan, includes a small-height cylindrical gasketand a pair of molds to be incorporated in the gasket. The gasket has aring-like projection which is formed on its inner wall surface in thecircumferential direction. When the pair of molds are incorporated inthe gasket, they are positioned by the projection.

When incorporating the pair of molds in the gasket, if a mold isinclined with respect to the axis of the gasket or the gap between thepair of molds is excessively large or small, lens thickness becomesnonuniform (prism defect) or insufficient to lead to a defectiveproduct. For this reason, various types of devices have beenconventionally proposed to incorporate the two molds not to be inclined(for example, Japanese Patent Laid-Open Nos. 55-123430 and 2001-512383).

The method of forming a lens-forming casting mold described in JapanesePatent Laid-Open No. 55-123430 includes the step of positioning andholding two molds by a reference plate such that their lens-formingoptical surfaces establish a predetermined positional relationship(reference positions for forming lens optical surfaces) and separatingthe two molds from the reference plate, the step of removing thereference plate, the step of setting a gasket at a position where thereference plate has been removed, and the step of returning the twomolds to the reference positions for forming the lens optical surfacesand fitting them in the gasket.

According to the lens-forming casting mold described in JP Pat.Laid-Open No. 2001-512383, a rear casting mold (mold) which forms theconcave surface of a lens is pushed into a gasket by a linear actuator.

SUMMARY OF THE INVENTION

The conventional methods of assembling the plastic-lens-forming castingmold described above have the following problems.

The method of forming a lens-forming casting mold described in JapanesePatent Laid-Open No. 55-123430 includes the step of positioning thelens-forming optical surfaces of the two molds at the referencepositions for forming lens optical surfaces by the reference plate inadvance, the step of separating the molds from the reference plate, thestep of replacing the reference plate with the gasket, and the step ofpushing the two molds into the gasket and returning them to the originalpositions (reference positions for forming the lens optical surfaces).Thus, operation of replacing the reference plate with the gasket isrequired, so that assembly of the casting mold takes a long period oftime. A plurality of types of reference plates need be prepared inaccordance with the types (sizes and dioptric powers) of the lenses, andstorage and management of the lenses become cumbersome.

According to the lens-forming casting mold described in JP Pat.Laid-Open No. 2001-512383, a pneumatic gripper provided to a robot armis detachably engaged with the front surface of a front casting mold tohold the gasket, and the rear casting mold is pushed into the gasket bythe linear actuator. Thus, the reference plate described in JapanesePatent Laid-Open No. 55-123430 is not needed, and the assembling time ofthe casting mold can be shortened, which are advantageous. However,according to this lens-forming casting mold, the pneumatic gripper isfitted on the outer surface of the gasket to hold the gasket. Thus, aplurality of types of pneumatic grippers need to be prepared inaccordance with the types (sizes and dioptric powers) of the lenses, inthe same manner as in Japanese Patent Laid-Open No. 55-123430, andaccordingly storage and management of the lenses become cumbersome.

According to the plastic lens manufacturing method described in JapanesePatent Publication No. 6-98631, the push-moving amount of the lower moldis determined by the height of the step of the pushing die which is tobe pushed into the gasket. A plurality of types of pushing dies havingsteps with different heights need to be prepared in accordance with thetypes of the lenses, and storage and management of the lenses arecumbersome.

It is an object of the present invention to solve the conventionalproblems described above and provide an assembling device for aplastic-lens-forming casting mold in which a gasket and two molds can beincorporated automatically and highly accurately such that the lensthickness will not become nonuniform or insufficient.

It is another object of the present invention to provide an assemblingmethod for a plastic-lens-forming casting mold which can assemble agasket and two molds automatically and highly accurately and which canbe applied easily to various types of casting molds.

In order to achieve the above object, there is provided an assemblingdevice for a plastic-lens-forming casting mold, comprising a gasketclamping mechanism which clamps a casting gasket from an axial directionthereof, a first mold push-in mechanism which pushes one mold fitted inone open end of the casting gasket into the casting gasket, and a secondmold push-in mechanism which pushes the other mold fitted in the otheropen end of the casting gasket into the casting gasket to oppose the onemold at a predetermined gap.

In order to achieve the above object, there is provided an assemblingmethod for a plastic-lens-forming casting mold, comprising the step offitting and temporarily fixing a pair of molds in two open ends of acasting gasket integrally having a positioning projection projectingfrom an inner surface of the casting gasket such that lens-formingoptical surfaces of the pair of molds come inside, the step of clampingthe casting gasket by a pair of clamping means from an axial direction,the first mold push-in step of pushing one of the pair of molds into thegasket by first push-in means to urge the mold against the projection,and the second mold push-in step of pushing the other mold into thegasket by second push-in means for a predetermined amount.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is an exploded sectional view before assembly of aplastic-lens-forming casting mold which is to be assembled by anassembling device according to the present invention;

FIG. 2 is a sectional view showing a state wherein molds are temporarilyfixed to a gasket;

FIG. 3 is a sectional view showing a state wherein the molds areincorporated in the gasket to form a plastic-lens-forming casting mold;

FIG. 4 is a perspective view of the main part of the assembling device;

FIG. 5 is a front view of the main part of the assembling device;

FIG. 6 is a sectional view taken along the line VI-VI of FIG. 5;

FIG. 7 is a sectional view taken along the line VII-VII of FIG. 5;

FIG. 8 is a plan view of a second mold push-in mechanism and shows therelationship between push pins and a lower mold ring for a lens having astandard diameter of 70 mm;

FIG. 9 is a view showing the relationship between the push pins and alower mold ring for a lens having a standard diameter of 60 mm;

FIG. 10 is a view showing the relationship between the push pins and alower mold ring for a lens having a standard diameter of 80 mm;

FIG. 11 is a sectional view of the main part in a state wherein theplastic-lens-forming casting mold is set on the lower mold ring;

FIG. 12 is a control block diagram of the assembling device;

FIG. 13 is a block diagram showing a position control circuit;

FIG. 14 is a view for explaining the assembling operation of theplastic-lens-forming casting mold;

FIG. 15 is a view for explaining the assembling operation of theplastic-lens-forming casting mold;

FIG. 16 is a view for explaining the assembling operation of theplastic-lens-forming casting mold;

FIG. 17 is a sectional view of the main part to show another embodimentof the present invention; and

FIG. 18 is a view showing a push pin height adjusting mechanism.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An assembling device and method for a plastic-lens-forming casting moldaccording to the present invention will be described in detailexemplifying an embodiment shown in the accompanying drawings.

Referring to FIGS. 1 to 3, a plastic-lens-forming casting mold which isdenoted by reference numeral 1 includes a gasket 2 and a pair of molds 3and 4 to be incorporated in the gasket 2. The gasket 2 is integrallyformed by injection molding of a synthetic resin to include acylindrical body 2A and an injecting portion 2B which integrallyprojects from an intermediate portion in the direction of height of theouter surface of the cylindrical body 2A. The two molds 3 and 4 areincorporated in the vertical gasket 2 from above and below,respectively. Hence, in the following description, one mold 3 which ison the upper side will also be called the upper mold 3, and the othermold 4 which is on the lower side will also be called the lower mold 4.

The cylindrical body 2A has a ring-like projection 5 which integrallyprojects from an intermediate portion in the direction of height of theinner surface of the cylindrical body 2A. The projection 5 has atriangular section and accordingly has an upper surface 5 a and inclinedsurface 5 b which intersect with the axis of the cylindrical body 2A atappropriate angles. The upper surface 5 a forms a support surface whichreceives and supports the peripheral portion of a concave surface 3 b ofthe upper mold 3.

The section of the ring-like projection 5 is not limited to a trianglebut can have any shape, e.g., a trapezoid or square, as far as it canreceive and support the upper mold 3. The projection 5 need not have acontinuous ring-like shape, but can be a plurality of discontinuousprojections which are interrupted at appropriate gaps in thecircumferential direction. Note that the projection 5 is not necessarywhen the upper mold 3 can be pushed into the gasket 2 not to beinclined, or when a semi-finished lens (a lens in which only a convexsurface is optically finished) which does not require so strict anaccuracy in the lens thickness is to be formed.

The cylindrical body 2A has a monomer injection port 6 formed in itsouter surface. The monomer injection port 6 is formed at a portion whichis immediately under the projection 5 and corresponds to the injectingportion 2B. The monomer injection port 6 forms a slit elongated in thecircumferential direction of the cylindrical body 2A to allow theinteriors of the cylindrical body 2A and injecting portion 2B tocommunicate with each other.

The cylindrical body 2A also has mold guides 7 and 8 and tapers 9 and 10formed at the openings at the two ends of its inner surface. The moldguides 7 and 8 serve to hold the corresponding molds 3 and 4 withappropriate frictional forces and temporarily fix them not to disengagenaturally. The outer diameter of each of the mold guides 7 and 8 isequal to an outer diameter D of the cylindrical body 2A. An innerdiameter d of each of the mold guides 7 and 8 is substantially equal toan outer diameter D₁ (D>D₁) of each of the molds 3 and 4. Lengths L₁ andL₂ (length in the axial direction of the cylindrical body 2A) of themold guides 7 and 8 are smaller than edge thicknesses LA and LB of themolds 3 and 4, respectively. The tapers 9 and 10 are formed inside themold guides 7 and 8, respectively.

The state wherein the molds 3 and 4 “do not disengage naturally” refersto a state wherein the inner diameter d of each of the mold guides 7 and8 is slightly smaller than the mold outer diameter D₁ (d<D₁) and, if thegasket material is flexible, when the molds 3 and 4 are lightly pushed,they can easily fit in the mold guides 7 and 8, respectively. Thus, inthe state wherein the molds 3 and 4 fit in the mold guides 7 and 8,respectively, the lower mold 4 will not be removed from the gasket 2.Even when the gasket 2 is turned upside down, the upper mold 3 will notbe removed from the gasket 2.

The tapers 9 and 10 of the gasket 2 serve as guide portions which definethe fitting sizes of the molds 3 and 4 with respect to the cylindricalbody 2A and allow the molds 3 and 4 to be pushed into the cylindricalbody 2A when the molds 3 and 4 are temporarily fixed. For this purpose,the tapers 9 and 10 form tapered surfaces that are inclined such thattheir diameters decrease toward the inner side of the cylindrical body2A. An inner diameter d₁ of the central portion of the inner surface(the inner surface between the tapers 8 and 9) of the cylindrical body2A is constant and naturally set smaller than the outer diameter D₁ ofeach of the molds 3 and 4. The tapers 9 and 10 of the gasket 2 allow theupper and lower molds 3 and 4 to be pushed into the gasket 2 with easeand are effective when preventing the inner surface of the gasket 2 frombeing worn by the mold.

When the upper mold 3 is fitted in the mold guide 7 of the gasket 2, itabuts against the taper 9 and is temporarily fixed, so that it will notbe inserted any further. When the upper mold 3 fitted in the mold guide7 is further pushed in by a first push-in means 58 (FIG. 6) (to bedescribed later), it passes through the taper 9 and is urged against theprojection 5. In this manner, since the upper mold 3 is finallypositioned by the projection 5, the positional accuracy of the uppermold 3 which is temporarily fixed by the mold guide 7 is not veryimportant. When the outer peripheral portion of the concave surface 3 bof the upper mold 3 is urged against the projection 5 entirely,inclination of the upper mold 3 is removed with respect to the uppermold 3, so that lens thickness difference will not be caused bydefective pushing. When the lower mold 4 is fitted in the mold guide 8,it abuts against the taper 10 and is temporarily fixed, so that it willnot be inserted any further.

The injecting portion 2B of the gasket 2 is a portion through which themonomer is injected into the cylindrical body 2A when forming a plasticlens. The injecting portion 2B is formed such that its longitudinalsectional shape which is parallel to the surface of the sheet of FIG. 1forms a trapezoidal funnel (see FIG. 4). An inner opening 12 of thecylindrical body 2A forms a horizontally elongated slit having a minimallongitudinal sectional area, and communicates with the injection port 6of the cylindrical body 2A. That opening 13 of the injecting portion 2Bwhich is opposite to the cylindrical body 2A side is rectangular and hasa maximal sectional area.

As the monomer material for a general spectacle lens, a thermoplasticmaterial such as a polyethylene-based resin, e.g., an ethylene-vinylacetate copolymer or ethylene-propylene copolymer, having a high degreeof polymerization shrinkage (about 7 to 15%) is used (for example,Japanese Patent Laid-Open Nos. 2-185586, 5-8230, 8-302336, 2000-191846,and 2000-190342). Of the materials disclosed in the above references, aparticularly preferable monomer material is a very-low-densitypolyethylene resin which is used in this embodiment. When a monomerhaving a high degree of polymerization shrinkage is to be filled in theplastic-lens-forming casting mold 1 and polymerized, the mold 4 (themold 3 too when a projection 5 for positioning the mold does not exist)is preferably moved to follow polymerization shrink of the monomer.Therefore, the gasket 2 is formed of a flexible (elastic) material to bedeformable in the direction of diameter, and allows movement of the mold4 in the axial direction.

As the gasket 2 is elastically deformable in the direction of diameter,it can fit with and hold the molds 3 and 4. More specifically, as shownin FIG. 3, when the molds 3 and 4 are pushed in deeper than the moldguides 7 and 8 of the cylindrical body 2A by a predetermined amount,they elastically deform in the direction of diameter because the innerdiameter d₁ of that portion of the cylindrical body 2A which is deeperthan the mold guide 7 or 8 is smaller than the outer diameter D₁ of eachof the molds 3 and 4. Therefore, the cylindrical body 2A deforms into abarrel shape. The restoration force of the cylindrical body 2A fastensthe outer surfaces of the molds 3 and 4 to hold them stably. When themolds 3 and 4 are completely extracted from the cylindrical body 2A, asshown in FIG. 1, or to the temporary fixing positions of the mold guides7 and 8, as shown in FIG. 2, the cylindrical body 2A is elasticallyrestored to the original shape so that its outer diameter D becomesconstant throughout its entire length. The holding force of thecylindrical body 2A for the molds 3 and 4 is substantially constantregardless of polymerization shrink of the monomer. The relationshipamong the outer diameter D₁ of each of the molds 3 and 4 and thematerial and shape of the gasket 2 is designed by considering thebehaviors of the gasket 2 and molds 3 and 4 during polymerization inadvance.

The pair of molds 3 and 4 respectively have meniscus shapes having thesame outer diameter D₁. The upper surface of one mold 3 forms a convexsurface 3 a which is curved moderately, and its lower surface forms theconcave surface 3 b which is also curved moderately. The convex surface3 a is not used as a lens surface and forms an arbitrary facing. Theconcave surface 3 b forms the transfer surface (lens forming opticalsurface) on the convex surface side of the plastic lens to be formed.Hence, the concave surface 3 b is planished with a predetermined radiusof curvature. Such a mold 3 is temporarily fixed as it is fitted withone mold guide 7 of the gasket 2 such that its concave surface 3 b comesinside (FIG. 2).

Similarly, the upper surface of the other mold 4 has a convex surface 4a and its lower surface has a concave surface 4 b. The mold 4 istemporarily fixed as it is fitted with the other mold guide 8 of thegasket 2 such that its convex surface 4 a comes inside. The convexsurface 4 a forms a curved surface having a radius of curvature smallerthan that of the concave surface 3 b of one mold 3, to form a transfersurface (lens-forming optical surface) on the concave surface side ofthe plastic lens to be formed. Hence, the convex surface 4 a isplanished with a predetermined radius of curvature. The concave surface4 b is not used as a lens surface and has an arbitrary facing. Theperipheral portion of the concave surface 4 b forms a ring-like flatsurface 4 c which is perpendicular to the optical axis regardless of themeniscus shape. When pushing in the mold 4 by a second push-in means 68(FIG. 6) (to be described later), the flat surface 4 c is effective inpreventing the mold 4 from being inclined. When the gasket 2 in whichthe molds 3 and 4 are temporarily fixed is set on a second clampingmeans 35 (see FIG. 6) (to be described later), the flat surface 4 c iseffective in setting the gasket 2 in a horizontal state. Morespecifically, the gasket 2 is set on the second clamping means 35 suchthat the peripheral portion of the lower mold 4 is fitted in a fittinggroove 38 of the second clamping means 35, as shown in FIG. 11, and isthen pressed from above by the first push-in means 58 (FIG. 6) (to bedescribed later), so that the entire lower end face of the gasket 2 isurged against the upper surface of the second clamping means 35. Theposition of height of the gasket 2 which is urged by the second clampingmeans 35 corresponds to the position of origin of the gasket 2.

The outer diameters of the molds 3 and 4 differ depending on thediameter of the lens to be manufactured. After the casting mold 1 isreleased, if the molded lens is to be machined to shape it to have apredetermined shape, the outer diameters of the molds 3 and 4 are set tobe larger than the lens diameter considering the machining margin of themachining.

Such a pair of molds 3 and 4 are fitted and temporarily fixed in themold guides 7 and 8, respectively, of the cylindrical body 2A, as shownin FIG. 2, and are pushed into the gasket 2 by an incorporating device20 (to be described later) and positioned at predetermined positions,thus completing assembly of the plastic-lens-forming casting mold 1. Inthis case, the upper mold 3 is positioned as the peripheral portion ofits concave surface 3 b abuts against the support surface 5 a of theprojection 5. Thus, the push-moving amount into the gasket 2 is constantregardless of the type of the lens to be formed.

The lower mold 4 is pushed in by a distance (push-moving amount) H (FIG.7) matching the type (dioptric power) of the lens to be formed, tooppose the upper mold 3 at a predetermined gap. Thus, the spacesurrounded by the gasket 2 and two molds 3 and 4 forms theplastic-lens-forming cavity 13 (FIG. 13) which communicates with theinterior of the injecting portion 2B through the injection port 6. Themonomer is injected into the cavity 13. In this case, naturally, thepair of molds 3 and 4 may be inverted upside down and incorporated inthe gasket 2 to assemble the plastic-lens-forming casting mold 1.

The structure, incorporating method, and the like of the incorporatingdevice 20 which is to incorporate the plastic-lens-forming casting mold1 will be described in detail.

Referring to FIGS. 4 to 6, the incorporating device 20 for theplastic-lens-forming casting mold 1 includes a housing 21, a gasketclamping mechanism 22 disposed in the housing 21, a first mold push-inmechanism 23 which pushes the upper mold 3 into the gasket 2, a secondmold push-in mechanism 24 which pushes the lower mold 4 into the gasket2, a mold push-moving amount adjusting mechanism 25 which adjusts thepush-moving amount H of the lower mold 4 in accordance with the type ofthe lens to be fabricated, and the like.

The gasket clamping mechanism 22 includes an upper plate 31 and lowerplate 32 which are disposed on a plurality of guide posts 29 verticallystanding upright on a base plate 28 of the housing 21 through linearbushes 30 to be vertically movable. The upper plate 31 includes thefirst mold push-in mechanism 23 and a first clamping means(gasket-pressing ring) 34. The lower plate 32 includes the detachablesecond clamping means (lower mold ring) 35 on which theplastic-lens-forming casting mold 1 is to be set.

The guide posts 29 extend through through holes formed in a top plate 40and the base plate 28, and their upper and lower ends are fixed to theplates 40 and 28 through shaft holders 41. The rear ends of the baseplate 28 and top plate 40 are connected to each other through a rearplate 42.

The lower plate 32 has a ring attaching hole 36 in its front end. Asshown in FIG. 11, the ring attaching hole 36 has different-diameterthrough holes formed of an upper large-diameter hole portion 36 a andlower small-diameter hole portion 36 b. The lower mold ring 35 isdetachably fitted in the large-diameter hole portion 36 a.

A lower surface 34 a of the gasket-pressing ring 34 forms a presssurface which presses the end face of the upper opening of the gasket 2.The gasket-pressing ring 34 is fixed to the lower surface of the frontend of the upper plate 31. A center hole 34 b of the gasket-pressingring 34 has a hole diameter sufficiently smaller than the inner diameterd of the gasket 2. The first incorporating means 58 of the first moldpush-in mechanism 23 is incorporated in the center hole 34 b.

Referring to FIG. 11, the lower mold ring 35 has a through hole 37having a hole diameter slightly smaller than the inner diameter d₁ ofthe gasket 2, and a fitting groove 38. The fitting groove 38 is formedof an annular groove which is formed in the opening of the upper end ofthe through hole 37 throughout the entire circumference. The downwardprojecting lower end of the gasket 2 is fitted with the peripheralportion of the mold 4. As the lower mold ring 35 of this type, aplurality of types having fitting grooves 38 with different innerdiameters are prepared to match the diameters of the lenses to beformed. The plurality of types of lower mold rings 35 have the sameouter diameter because any ring 35 must be able to be fitted in thelarge-diameter hole portion 36 a of the ring attaching hole 36 of thelower plate 32. In general, regarding the lower mold ring 35, since thestandard diameter of the lens includes five types, i.e., 60 mm, 65 mm,70 mm, 75 mm, and 80 mm, five types of rings 35 are prepared tocorrespond to the respective lenses.

Referring to FIG. 6, the gasket clamping mechanism 22 further includes agasket-pressing pneumatic cylinder (clamping driving unit) 45 whichvertically moves the upper plate 31 along the guide posts 29, and a mainpneumatic cylinder (gasket moving driving unit) 46 which verticallymoves the upper plate 31 and lower plate 32 integrally along the guideposts 29.

The gasket-pressing pneumatic cylinder 45 includes a cylinder main body45A which is set on the upper surface of the upper plate 31 to facedown, and a piston rod 45B which projects downward from the cylindermain body 45A. The piston rod 45B extends through an insertion hole 50of the upper plate 31 to be vertically movable in noncontact with theinsertion hole 50. The lower end of the piston rod 45B is connected to ajoint 51 arranged on the upper surface of the lower plate 32. The pistonrod 45B is usually held to be projecting (moving forward) from thecylinder main body 45A by a maximal stroke, to hold the upper plate 31at the highest initial position shown in FIG. 6. At this time, thegasket-pressing ring 34 and lower mold ring 35 are separate from eachother by the maximal stroke. In this state, when air supply to thecylinder main body 45A is switched to such a direction that the pistonrod 45B moves backward (upward), the piston rod 45B itself cannot moveupward as its lower end is fixed to the joint 51, and instead thecylinder main body 45A moves downward along the piston rod 45B togetherwith the upper plate 31. Hence, the gasket-pressing pneumatic cylinder45 moves downward together with the upper plate 31 to push down the mold3 to press it into the gasket 2. The pulling output of thegasket-pressing pneumatic cylinder 45, i.e., the force (press force)with which the gasket-pressing ring 34 presses the gasket 2 upondownward movement of the upper plate 31 and cylinder main body 45A, isset to, e.g., 495 N (Newton). Note that this press force is freelyadjustable by a regulator (not shown).

Referring to FIG. 7, the main pneumatic cylinder 46 includes a cylindermain body 46A which is set on the upper surface of the lower plate 32 toface down, and a piston rod 46B which projects downward from thecylinder main body 46A. The piston rod 46B extends through an insertionhole 33 formed in the lower plate 32 to be vertically movable innoncontact with the insertion hole 33. The lower end of the piston rod46B is connected to the base plate 28 through a joint 54. The piston rod46B is usually held to be projecting (moving forward) from the cylindermain body 46A by a maximal stroke, to hold the lower plate 32 at thehighest initial position with respect to an adjusting screw 87 of themold push-moving amount adjusting mechanism 25. In this state, when airsupply to the cylinder main body 46A is switched to such a directionthat the piston rod 46B moves backward (upward), the piston rod 46Bitself cannot move upward as it is fixed to the joint 54, and insteadthe cylinder main body 46A moves downward together with the lower plate32 to urge the lower mold 4 against the second mold push-in mechanism 24(FIG. 6). The pulling output of the main pneumatic cylinder 46 at thistime, i.e., the force (press force) with which the cylinder main body46A moves downward together with the lower plate 32 to urge the lowermold 4 against the second mold push-in mechanism 24, is set to a valuesufficiently larger than the press force of the gasket-pressingpneumatic cylinder 45, e.g., 1,400 N (Newton). Note that this pressforce is freely adjustable by a regulator (not shown).

Referring to FIG. 6, the first mold push-in mechanism 23 includes thefirst push-in means 58 (to be referred to as a push-in member) which isretractably fitted and inserted in the center hole 34 b of thegasket-pressing ring 34, and an upper-mold-pressing pneumatic cylinder59 which vertically moves the push-in member 58. The push-in member 58forms a disk having a circular frustoconical concave 60 at the center ofits lower surface. That flat surface of the push-in member 58 which isoutside the concave 60 forms a press surface 61 which presses the uppersurface 3 a of the upper mold 3. The push-in member 58 is usuallylocated in the gasket-pressing ring 34, and the press surface 61 isalmost flush with the lower surface 34 a of the gasket-pressing ring 34.The lower surface 34 a of the gasket-pressing ring 34 forms a gasketpress surface which presses the upper end face of the gasket 2.

The upper-mold-pressing pneumatic cylinder 59 includes a cylinder mainbody 59A which is set on the upper surface of the upper plate 31 to facedown, and a piston rod 59B which projects downward from the cylindermain body 59A. The piston rod 59B extends through an insertion hole 63formed in the upper plate 31 to be vertically movable in noncontact withthe insertion hole 63. The push-in member 58 is fixed to the lower endof the piston rod 59B. The pushing force of the upper-mold-pressingpneumatic cylinder 59, i.e., the force (press force) of the push-inmember 58 to push the upper mold 3 into the gasket 2, is set to a valuesmaller than the press force of the gasket-pressing pneumatic cylinder45, e.g., 254 N (Newton). Note that this press force is freelyadjustable by a regulator (not shown).

Referring to FIGS. 6 and 8, the second mold push-in mechanism 24includes an LM guide 65 which is set on the base plate 28, two slideplates 66 and 67 which are arranged movable to come close to andseparate from each other along the LM guide 65, and the second push-inmeans 68. The slide plates 66 and 67 are biased by a pin opening/closingpneumatic cylinder 70 in directions to separate from each other. The pinopening/closing pneumatic cylinder 70 is set on the base plate 28. Thesecond push-in means 68 includes a total of eight push pins 68 a to 68h, i.e., four push pins which project from the slide plate 66 and fourpush pins which project from the slide plate 67 substantiallyconcentrically. As the slide plates 66 and 67 are biased in theseparating directions, the push pins 68 a to 68 h are urged against thehole wall of the through hole 37 of the lower mold ring 35.

How the push pins 68 come into contact with the inner wall of the lowermold ring 35 differs depending on the diameter of the lens to befabricated. More specifically, when the lower mold ring 35 is for a lenshaving a standard diameter of 70 mm, all the push pins 68 a to 68 h arearrayed concentrically such that their outer surfaces come into contactwith the hole wall of the through hole 37, as shown in FIG. 8. When thelower mold ring 35 is for a lens having a standard diameter of 60 mm, asshown in FIG. 9, the two slide plates 67 and 68 are closer to each otherthan in a case of the lower mold ring 35 for a lens having a standarddiameter of 70 mm. Only the outer four push pins 68 a, 68 d, 68 e, and68 h standing at positions far from the LM guide 65 come into contactwith the hole wall of the through hole 37, while the inner four pushpins 68 b, 68 c, 68 f, and 68 g are separate from the hole wall. Whenthe lower mold ring 35 is for a lens having a standard diameter of 80mm, as shown in FIG. 10, the two slide plates 66 and 67 are separatefrom each other. Only the inner four push pins 68 b, 68 c, 68 f, and 68g standing at positions close to the LM guide 65 come into contact withthe hole wall of the through hole 37, while the outer four push pins 68a, 68 d, 68 e, and 68 h are separate from the hole wall.

In this manner, depending on the lens diameter, even if only some pushpins 68 are in contact with the hole wall of the through hole 37 of thelower mold ring 35 while the remaining push pins 68 are separate fromthe hole wall, the separate pins are not located completely inside theflat surface 4 c of the lower mold 4, but the upper surfaces of theseparate pins partially overlap the flat surface 4 c. Therefore, all thepush pins 68 can come into contact with the flat surface 4 c of thelower mold 4 without failure regardless of the lens diameter, thuscontributing to pushing in the lower mold 4.

Referring to FIG. 8, the pin opening/closing pneumatic cylinder 70includes a cylinder main body 70A which is fixed on one slide plate 66sideways, and a piston rod 70B which projects from the cylinder mainbody 70A and is connected to the other slide plate 67 through a joint71. Although the press force of the pin opening/closing pneumaticcylinder 70 is set to 11 N, it is not limited to this value, but can befreely adjusted by a regulator (not shown). When theplastic-lens-forming casting mold 1 in which the molds 3 and 4 arefitted and temporarily assembled in the respective open ends of thegasket 2 is set on the lower mold ring 35, as shown in FIG. 6, the eightpush pins 68 are inserted in the lower mold ring 35, and the uppersurfaces of the push pins 68 are located below the flat surface 4 c ofthe mold 4 in noncontact with the flat surface 4 c, as shown in FIG. 8.The layout of the plastic-lens-forming casting mold 1 is not limited tothis, but the lower mold 4 may be set on the upper surfaces of the pushpins 68. Although the pneumatic cylinder 70 is used as a means forbiasing the push pins 68 in the opening directions, the presentinvention is not limited to this, but a compression coil spring, tensioncoil spring, or the like may be used. Referring to FIG. 8, referencenumeral 73 denotes a stopper which limits the movement of the slideplates 66 and 67 to come close to each other; and 74, stays.

This embodiment exemplifies a case wherein all of the eight push pins 68a to 68 h are brought into contact with the hole wall of the lower moldring 35 for a lens having a standard diameter of 70 mm. If a lower moldring 35 for a lens having a standard diameter other than 70 mm isemployed, only four push pins are brought into contact with the holewall of the lower mold ring 35. However, the present invention is notlimited to this. For example, four to eight push pins 68 which areindependent of each other may be used. When these push pins 68 arearranged to be movable in radial directions from the center of the lowermold ring 35 and biased in opening directions (radial directions), allthe push pins 68 can be brought into contact with the hole walls of anyone of all lower mold rings 35 having different inner diameters.

Referring to FIGS. 4, 5, and 7, the mold push-moving amount adjustingmechanism 25 is used to set the push-moving amount (H) of the lower mold4 against the gasket 2 in advance in accordance with the type of thelens, and includes a stepping motor 74 and a spline shaft 75 which isrotated by the stepping motor 74. The stepping motor 74 is set on avertical attaching plate 77 through a bracket 78 to face down. The upperend of the spline shaft 75 is connected to an output shaft 79 of thestepping motor 74 through a coupling 80. The attaching plate 77 standsupright on a horizontal support plate 76 located above the lower plate32.

The spline shaft 75 extends through through holes 81, 82, and 83respectively formed in the support plate 76, lower plate 32, and baseplate 28 in noncontact with the through holes 81, 82, and 83. The lowerend of the spline shaft 75 is rotatably, axially supported by a bearing85 fixed on a bottom plate 84 (FIG. 5) of the housing 21. The adjustingscrew 87 is fitted on the spline shaft 75 through a spline bearing 88.The adjusting screw 87 threadably engages with a stationary nut 89 fixedto the lower surface of the base plate 28, and its upper end projectsabove the base plate 28. The spline bearing 88 is fitted and fixed inthe lower open end of the adjusting screw 87, and slidably fits with aspline 75A of the spline shaft 75 through spline coupling.

A stopper 91 is fixed to the lower surface of the distal end of thelower plate 32 to correspond to the adjusting screw 87. The distancebetween the adjusting screw 87 and stopper 91 is a distance that matchesthe type of the lens to be fabricated, i.e., the push-moving amount H ofthe lower mold 4. The stopper 91 forms a ring, and the spline shaft 75extends through the center hole of the stopper 91 to be verticallymovable.

The adjusting screw 87 is usually held at the lowest position (positionof origin), and is driven by the stepping motor 74 to move upward to adesired height position when setting the push-moving amount H of thelower mold 4. More specifically, when the stepping motor 74 is driven,the rotation of the output shaft 79 is transmitted to the spline shaft75 through the coupling 80, and the rotation of the spline shaft 75 istransmitted to the adjusting screw 87 through the spline bearing 88.Accordingly, the adjusting screw 87 moves upward to a desired height,while rotating with respect to the stationary nut 89, and stops to setthe predetermined push-moving amount H with respect to the stopper 91.In this mold push-moving amount adjusting mechanism 25, even if thepress force of the main cylinder 46 is applied as a load to theadjusting screw 87 through the stopper 91, no load is applied to therotating portion of the stepping motor 74 due to the spline connectionof the spline shaft 75 and spline bearing 88. Accordingly, the rotationof the stepping motor 74 is smoothly transmitted to the adjusting screw87 through the spline connection of the spline shaft 75 and splinebearing 88.

The push-moving amount (distance H) of the lower mold 4 is (X−Xi) whereX is the maximal distance from the adjusting screw 87 to the lowersurface of the stopper 91 when the adjusting screw 87 is moved to thelowest position by operating the origin, and Xi is the moving distance(variable value) of the upward movement of the adjusting screw 87 fromthe position of origin which is set for every dioptric power of thelens. The variable value Xi is determined considering the shapes of themolds 3 and 4 according to the prescription of the lens, the preset lensthickness, the adjusting amounts of the movements of the molds 3 and 4required due to the polymerization shrink of the monomer and thermaldeformation of the gasket 2 during the thermal polymerization process,the deformation amount of the gasket 2 due to assembly of the molds 3and 4, the relationship between the lower mold ring 35 and push pins 68,and the like.

The rate of polymerization shrink of the monomer differs depending onthe lens material. Similarly, the thermal deformation amount of thegasket 2 differs depending on the gasket material. Shape factorsincluding the thickness of the gasket 2 and shape factors of the molds 3and 4 also adversely affect thermal deformation. Accordingly, as thepush-moving amount H, a verified value which is obtained fromexperimental composite data of all of these factors is used.

Referring to FIG. 5, reference numeral 93 denotes a first origin sensor.The origin sensor 93 comprises a photosensor and is attached to a firststay 99A which stands upright on the bottom plate 84. The first originsensor 93 detects a slit 97 a of a sensor slit cam 97 attached to thespline shaft 75 to optically detect the rotational angle, necessary forstopping, of the spline shaft 75.

Reference numeral 94 denotes a second origin sensor; 95, a lower limitsensor; and 96, an upper limit sensor. The sensors 94, 95, and 96 aresimilarly attached to a second stay 99B which also stands upright on thebottom plate 84. The second origin sensor 94 comprises a reflectingphotoelectric sensor, and optically detects a sensor disk 98 attached tothe adjusting screw 87 to detect the height of the initial position ofthe adjusting screw 87. The lower limit sensor 95 and upper limit sensor96 are sensors which detect the sensor disk 98 when the adjusting screw87 overruns down or up. A detection signal from the second origin sensor94 stops driving of the stepping motor 74. As the lower limit sensor 95and upper limit sensor 96, reflecting photoelectric sensors aresimilarly used. However, the lower limit sensor 95 and upper limitsensor 96 are not limited to reflecting photoelectric sensors, but maybe limit switches.

Referring to FIG. 12, a program controller 100 which controls the entireassembling device 20 includes an I/O controller 102, motor positioningcontroller 103, and computer interface 104. The I/O controller 102,motor positioning controller 103, and computer interface 104 areconnected through a data bus 105 and managed by a CPU 101. The I/Ocontroller 102 is connected to the gasket-pressing pneumatic cylinder45, upper-mold-pressing pneumatic cylinder 59, pin opening/closingpneumatic cylinder 70, and main pneumatic cylinder 46 throughelectromagnetic valves 110 a to 110 d, respectively, to receive signalsfrom input/output units of an operation panel 111. The motor positioningcontroller 103 is connected to the stepping motor 74 through a motordriver 112, as well as to the first and second origin sensors 93 and 94,lower limit sensor 95, and upper limit sensor 96. The computer interface104 is connected to an external personal computer 121.

Upon reception of a signal sent from the input unit (an operation switchor setting unit) of the operation panel 111 through the I/O controller102, the CPU 101 performs the process for the entire device inaccordance with preset programming. More specifically, in response to acommand, the CPU 101 sequentially drives the electromagnetic valves 110a to 110 d through the I/O controller 102 to operate the gasket-pressingpneumatic cylinder 45, upper-mold-pressing pneumatic cylinder 59, pinopening/closing pneumatic cylinder 70, and main pneumatic cylinder 46,respectively. The CPU 101 also sends a positioning command to the motorpositioning controller 103. In response to the positioning command, themotor positioning controller 103 sends a driving signal to the steppingmotor 74 of the mold push-moving amount adjusting mechanism 25 throughthe motor driver 112. The stepping motor 74 is driven by the drivingsignal from the motor positioning controller 103 to rotate the splineshaft 75 (FIGS. 5 and 7). As a result, the adjusting screw 87 movesupward to a desired height position and stops there to set apredetermined push-moving amount H with respect to the stopper 91.

Referring to FIG. 13, when push-moving amount data is input to the CPU101 from the operation panel 111 or the input unit of the personalcomputer 121, the CPU 101 converts the data into a pulse amount andtransmits it to the motor positioning controller 103 through the databus 105. The motor positioning controller 103 is a unit which controlsthe motor driver 112 by a pulse train. The motor positioning controller103 converts the pulse amount data set by the CPU 101 into a pulse trainand outputs it to the stepping motor 74 through the motor driver 112.The stepping motor 74 rotates by a rotation count corresponding to thegiven pulse amount to move the adjusting screw 87 upward. The steppingmotor 74 includes an encoder to detect the rotational position. Adetection signal from the encoder is fed back to the motor driver 112 tocontrol the position of the adjusting screw 87 highly accurately. Themotor positioning controller 103 detects the sensor disk 98 (FIG. 5) bythe second origin sensor 94 to position the adjusting screw 87 at theinitial height. When the first origin sensor 93 detects the slit 97 a ofthe sensor slit cam 97, the motor positioning controller 103 determinesthe detected position as the position of origin of the adjusting screw87.

The assembling procedure of the plastic-lens-forming casting mold 1 bythe assembling device 20 will be described.

The assembling method for the casting mold 1 shown in FIGS. 1 to 3 willbe described.

First, a gasket 2 and molds 3 and 4 (FIG. 1) matching a lens to beformed are selected and prepared. The adjusting screw 87 held at theposition of origin is moved upward by a predetermined amount to set inthe assembling device 20 the push-moving amount H (FIG. 7) which isrequired to push the mold 4 into the gasket 2.

When setting the push-moving amount H, the operator inputs push-movingamount data which matches the mold 4 into the I/O controller 102 (FIGS.12 and 13) via the operation panel 111 or the input unit of the personalcomputer 121 (FIG. 13). When the push-moving amount data is input to theI/O controller 102, the CPU 101 converts the data into a pulse count, asdescribed above, and transmits it to the motor positioning controller103. The motor positioning controller 103 sends a driving signal to themotor driver 112 to drive the stepping motor 74. Upon reception of apulse signal from the motor driver 112, the stepping motor 74 rotates bya rotation count corresponding to the pulse count to move the adjustingscrew 87 upward. More specifically, when the stepping motor 74 isdriven, the rotation of its output shaft 79 (FIG. 7) is transmitted tothe spline shaft 75 through the coupling 80. The rotation of the splineshaft 75 is transmitted to the adjusting screw 87 through thespline-coupled spline bearing 88. Accordingly, the adjusting screw 87rotates together with the spline shaft 75. As the adjusting screw 87threadably engages with the stationary nut 89, it moves upward to apredetermined height along the stationary nut 89 and stops to set thepredetermined push-moving amount H with respect to the stopper 91.

Subsequently, a lower mold ring 35 (FIG. 6) which matches the size ofthe lens to be formed is selected, and fitted in the large-diameter holeportion 36 a of the fitting hole 36 of the lower plate 32. The pair ofmolds 3 and 4 are pressed into the gasket 2 and temporarily assembledwith the mold guides 7 and 8, respectively, such that the lens-formingoptical surfaces 3 b and 4 a oppose each other (FIG. 2). In this state,the central portion of the upper surface of the upper mold 3 projectsupward from the upper surface of the gasket 2. Part of the peripheralportion of the lower mold 4 projects downward from the lower surface ofthe gasket 2.

The plastic-lens-forming casting mold 1 in this temporarily assembledstate is set on the lower mold ring 35 (FIGS. 6 and 11). The castingmold 1 is set by fitting that portion of the peripheral portion of thelower mold 4 which projects downward from the gasket 2 in the fittinggroove 38 of the lower mold ring 35. In this state, the lower end of thegasket 2 is not yet in contact with the upper surface of the lower moldring 35 (FIG. 11). The molds 3 and 4 may be temporarily assembled in thegasket 2 manually, or automatically using a robot or the like. The orderof adjusting the push-moving amount H by the mold push-moving amountadjusting mechanism 25 and mounting the plastic-lens-forming castingmold 1 in the lower mold ring 35 may be reversed.

When the plastic-lens-forming casting mold 1 is set on the lower moldring 35, the gasket-pressing ring 34 and gasket-pressing ring 34 clampthe gasket 2 from the axial direction (FIG. 14). The step of clampingthe gasket 2 by the gasket-pressing ring 34 and lower mold ring 35 isperformed by operating the gasket-pressing pneumatic cylinder 45, movingthe piston rod 45B backward to move the upper plate 31 downward, andurging the lower surface 34 a of the gasket-pressing ring 34 against theupper surface of the upper mold 3. More specifically, when thegasket-pressing ring 34 is urged against the upper mold 3, the uppermold 3 is pushed into the gasket 2. When the upper mold 3 is completelypushed into the gasket 2, the lower surface 34 a of the gasket-pressingring 34 presses the upper end face of the gasket 2 to urge the lower endface of the gasket 2 against the upper surface of the lower mold ring35. Thus, the gasket 2 is clamped by the gasket-pressing ring 34 andlower mold ring 35 from the axial direction. FIG. 14 shows this state.

When the upper mold 3 is pushed into the gasket 2 by the gasket-pressingring 34, the upper mold 3 rides over the taper 9 to elastically deformthe upper end of the gasket 2 outwardly, thus enlarging the diameter ofthe gasket 2.

Then, the upper-mold-pressing pneumatic cylinder 59 is driven to extendthe piston rod 59B out from the cylinder main body 59A (FIG. 15). Whenthe piston rod 59B moves downward, it projects the push-in member 58below the gasket-pressing ring 34 to urge the push-in member 58 againstthe upper mold 3. Therefore, the upper mold 3 is further pushed into thegasket 2 by the push-in member 58 and urged against the ring-likeprojection 5 (FIG. 3) projecting from the inner surface of the gasket 2.At this time, since the output from the gasket-pressing pneumaticcylinder 45 is set to be larger than the output from theupper-mold-pressing pneumatic cylinder 59, when the push-in member 58 isurged against the upper mold 3, the gasket-pressing ring 34 whichpresses the gasket 2 will not move upward to be restored together withthe upper plate 31 to release the gasket 2. The inner diameter d₁ of thegasket 2 is set smaller than the outer diameter D₁ of the upper mold 3.Thus, when the upper mold 3 is pushed into the gasket 2, the gasket 2elastically deforms in the diameter-enlarging directions, and fastensand holds the upper mold 3 with its restoration force.

When the first mold push-in step by the push-in member 58 is ended, thelower mold 4 is pushed into the gasket 2 in the second mold push-in step(FIG. 16). The second mold push-in step is performed by driving the mainpneumatic cylinder 46 (FIG. 7). More specifically, when the mainpneumatic cylinder 46 is driven, its piston rod 46B moves backward tomove the lower plate 32 downward by a predetermined distance. At thistime, since the upper plate 31 is coupled to the lower plate 32 throughthe gasket-pressing pneumatic cylinder 45, it moves together with thelower plate 32 while maintaining a predetermined gap from the lowerplate 32. Therefore, the gasket 2 is clamped by the gasket-pressing ring34 and lower mold ring 35, and maintains a state wherein the upper mold3 is pressed by the push-in member 58.

When the downward movement of the upper plate 31 and lower plate 32moves the gasket 2 downward, the lower surface 4 c of the lower mold 4which is fitted in the lower mold ring 35 comes into contact with theupper surfaces of the push pins 68. After coming into contact with thepush pins 68, the lower mold 4 further moves downward by a predetermineddistance. Accordingly, the lower mold 4 is pushed up by the push pins 68to ride over the taper 10 of the gasket 2, so that it is pushed into thegasket 2 (FIG. 16). When the stopper 91 fixed to the lower plate 32abuts against the upper surface of the adjusting screw 87, the lowerplate 32 stops to end the push-in operation of the mold 4 by the pushpins 68. When the lower plate 32 stops, the upper and lower molds 3 and4 oppose each other at a predetermined gap, and the space surrounded bythe molds 3 and 4 and gasket 2 forms a cavity 13. When the lower mold 4is pushed into the gasket 2, the gasket 2 elastically deforms in thediameter-enlarging directions to fasten and hold the lower mold 4.Consequently, the gasket 2 deforms into a barrel shape having a largeouter diameter at its center in the direction of height (FIG. 3).

To push the lower mold 4 into the gasket 2 by a predetermined amount,the distance H from the upper surface of the adjusting screw 87 to thelower surface of the stopper 91 may be determined for each lens. Thegasket 2 moves downward vertically as it is clamped by thegasket-pressing ring 34 and lower mold ring 35. Thus, the lower mold 4will not be inclined with respect to the gasket 2, but is pushed inaccurately by the push pins 68.

After a state wherein the mold 4 is pushed into the gasket 2 by the pushpins 68 and the stopper 91 is urged against the adjusting screw 87continues for a predetermined period of time, the upper-mold-pressingpneumatic cylinder 59 moves the piston rod 59B backward to release theupper mold 3 which has been pressed by the push-in member 58. When thegasket-pressing pneumatic cylinder 45 and main pneumatic cylinder 46 aredriven to extend both the piston rods 45B and 46B, the gasket clampingmechanism 22 is restored to the initial state. As a result, the gasket 2is released from the gasket-pressing ring 34 and lower mold ring 35, andautomatic assembly of the gasket 2 and pair of molds 3 and 4 iscompleted.

After the assembling operation of the molds 3 and 4 by the assemblingdevice 20 is completed, the retreating operation of retreating thepush-in member 58 from the mold 3 is preferably performed after it isconfirmed that the gasket 2 temporarily, elastically deforms into abarrel shape to clamp the molds 3 and 4 stably. This is because the timelag of the flexibility of the gasket 2 must be considered.

With this assembling device 20, since the plastic-lens-forming castingmold 1 can be assembled automatically, the assembling workability can beimproved. Also, variations in assembly are small, so that the molds 3and 4 can be assembled in the gasket 2 highly accurately. Thepush-moving amount H required when assembling the lower mold 4 can bevariably set by the mold push-moving amount adjusting mechanism 25 inaccordance with the lens to be formed. Thus, various types ofplastic-lens-forming casting molds can be assembled.

With the assembling device 20, the slide plates 66 and 67 (FIGS. 8 to10) are biased in the opening directions and the push pins 68 which pushthe lower mold 4 into the gasket 2 are brought into contact with thehole wall of the lower mold ring 35. Thus, the push pins 68 can becommonly used for various types of lower mold rings 35 having differentinner diameters, so that the device can be handled simply and easily.

With the assembling device 20, the gasket 2 is clamped by thegasket-pressing ring 34 and lower mold ring 35 from only the axialdirection. Thus, when pushing in the molds 3 and 4, the gasket 2 can beelastically deformed in the diameter-enlarging directions, so that itcan be pushed in reliably.

FIG. 17 is a sectional view of the main part showing another embodimentof the present invention, and FIG. 18 is a view showing a push pinheight adjusting mechanism.

With the assembling device according to this embodiment, a mold 4 withits lens-forming optical surface 4 a facing down is pushed into a gasket2 from the upper open end of the gasket 2 by a push-in member 58, andurged against a support surface 5 a of a projection 5. A mold 3 with itslens-forming optical surface 3 b facing up is pushed into the gasket 2from the lower open end of the gasket 2 by a plurality of push pins 68.The assembling device includes height adjusting mechanisms 130 for thepush pins 68 which adjust the heights of the respective push pins 68individually and independently of each other.

Each height adjusting mechanism 130 includes a rack 131 which is formedaround the corresponding push pin 68, a pinion 132 which is formed on aslide plate 66 (67) and meshes with the rack 131, and a motor (notshown) which rotates the pinion 132. The motor is not limited to this,but may be a pneumatic cylinder or the like. The push pins 68 need nothave the same length, but can be exchanged for push pins 68 havingdifferent lengths.

With the assembling device having the above structure, since the heightsof the respective push pins 68 can be adjusted by the height adjustingmechanisms 130 individually and independently of each other, the lowermold 3 can be incorporated to be inclined with respect to the upper mold4. Thus, a prism lens used for eye position correction can befabricated.

The above embodiment shows the vertical assembling device 20 in whichthe gasket 2 is set vertically and clamped from above and below by thegasket-pressing ring 34 and lower mold ring 35. However, the presentinvention is not limited to this at all, but can also be applied to ahorizontal assembling device in which the gasket 2 is set horizontallyand clamped from the horizontal direction. In this case, as the lowermold ring 35 is set horizontally, the peripheral portion of the mold 4is fitted in the fitting groove 38 of the horizontal lower mold ring 35from the horizontal direction. Accordingly, the casting mold can readilyfall from the lower mold ring 35. In this case, the gasket 2 ispreferably supported by an appropriate support means until it iscompletely clamped by a gasket-pressing ring 34 and lower mold ring 35.

In the above embodiment, while the gasket 2 is clamped by thegasket-pressing ring 34 and lower mold ring 35, the lower plate 32 ismoved downward to urge the lower mold 4 against the push pins 68. As thelower mold 4 and push pins 68 operate relative to each other, the lowermold 4 may be pushed into the gasket 2 by the upward movement of thepush pins 68.

In the above embodiment, pneumatic cylinders are used as the drivingsources for the clamping driving unit 45, gasket-moving driving unit 46,and mold-pressing driving unit 59. However, the driving sources are notlimited to the pneumatic cylinders, but motors may be used.

With the assembling device for the plastic-lens-forming casting moldaccording to the above embodiment, the gasket only need be clamped fromthe axial direction. This enables the gasket to elastically deform inthe diameter-enlarging directions when the molds are pushed into thegasket, so that the molds can be pushed in reliably and highlyaccurately.

According to the above embodiment, the plastic-lens-forming casting moldcan be assembled automatically, and accordingly the assemblingworkability can be improved.

With the assembling device of the embodiment described above, thepush-moving amount required when pushing in the molds can be freely set.Thus, various types of plastic-lens-forming casting molds can beassembled.

With the assembling device of the embodiment described above, the moldsare pushed in by using openable/closeable push pins. The assemblingdevice can be commonly used for a plurality of types of casting moldshaving different diameters only by preparing the second clamping meanshaving a different inner diameter. Thus, the device can be handledsimply and easily.

With the assembling device of the embodiment described above, theheights of the push pins can be adjusted individually and independentlyof each other. Thus, a prism lens can also be fabricated, and theversatility of the device can be increased.

With an assembling method for a plastic-lens-forming casting mold of theembodiment described above, the gasket is clamped from the axialdirection and the pair of molds are pushed in sequentially. The gasketcan be elastically deformed in the diameter-enlarging directions bypushing in the molds. Thus, the molds can be incorporated in the gasketreliably and highly accurately.

With the assembling method of the embodiment described above, aplurality of openable/closeable push pins are used as the second push-inmeans. Thus, the assembling method can be commonly applied to aplurality of types of casting molds having different diameters. Also,since the heights of the push pins can be adjusted individually andindependently of each other, a prism lens can be fabricated.

With the assembling method of the embodiment described above, a flatsurface formed on the peripheral portion of that surface of the othermold which is opposite to the lens-forming optical surface is pressed bythe second push-in means. Thus, the other mold can be incorporatedaccurately without being inclined, thus improving the accuracy of lensthickness control.

The assembling method of the embodiment described above comprises thestep of setting the push-moving amount of the other mold. Thus, theaccuracy of lens thickness control is further improved, and a pluralityof types of plastic-lens-forming casting molds can be assembled.

As has been described above, the assembling device and method accordingto the present invention are effectively used in the assembly of aplastic-lens-forming casting mold.

1. An assembling device for a plastic-lens-forming casting moldcharacterized by comprising a gasket clamping mechanism which clampseach end face of a casting gasket from an axial direction thereof. afirst mold push-in mechanism which pushes one mold fitted in one openend of said casting gasket into said casting gasket, and a second moldpush-in mechanism which pushes the other mold fitted in the other openend of said casting gasket into said casting gasket to oppose said onemold at a predetermined gap.
 2. An assembling device for aplastic-lens-forming casting mold according to claim 1, characterized inthat said gasket clamping mechanism and second mold push-in mechanismare disposed to be able to relatively come close to and separate fromeach other.
 3. An assembling device for a plastic-lens-forming castingmold according to claim 1, characterized in that said gasket clampingmechanism includes first and second clamping means which oppose eachother and is disposed such that at least one of said first and secondclamping means is able to come close to and separate from the other toclamp said casting gasket from the axial direction, and a clampingdriving unit which drives at least one of said first and second clampingmeans, and said casting gasket is set on said second clamping meanswhile said molds are fitted in two open ends of said gasket, and saidsecond clamping means has a fitting groove which fits on a peripheralportion of the other mold which is pushed in by said second mold push-inmechanism.
 4. An assembling device for a plastic-lens-forming castingmold according to claim 3, characterized in that said gasket clampingmechanism includes two opposing plates which are disposed to be slidablealong a guide post, one of said two plates includes first clamping meansand a clamping driving unit which moves said one plate along said guidepost to urge said first clamping means against one open end face of saidcasting gasket, and the other one of said two plates includes detachablesecond clamping means and a gasket-moving driving unit which integrallymoves said two plates toward said second mold push-in mechanism alongsaid guide post while said first and second clamping means clamp saidcasting gasket.
 5. An assembling device for a plastic-lens-formingcasting mold according to claim 3, characterized in that said first moldpush-in mechanism includes a mold push-in member which is reciprocallyfitted and inserted in said first clamping means, and a mold push-indriving unit which urges said mold push-in member against acorresponding one of said molds, and said second mold push-in mechanismincludes a plurality of push pins which are biased in enlargingdirections to abut against an inner surface of said second clampingmeans.
 6. An assembling device for a plastic-lens-forming casting moldaccording to claim 5, characterized in that said push pins are disposedsuch that heights thereof are adjustable.
 7. An assembling device for aplastic-lens-forming casting mold according to claim 1, characterized byfurther comprising a mold push-moving amount adjusting mechanism whichadjusts a mold push-moving amount of said second mold push-in mechanism.8. An assembling device for a plastic-lens-forming casting moldaccording to claim 7, characterized in that said mold push-moving amountadjusting mechanism includes a spline shaft, an adjusting driving unitwhich rotates said spline shaft, an adjusting screw which is slidablyspline-coupled to said spline shaft, a stationary nut which threadablyengages with said adjusting screw, and a stopper which is provided tosaid gasket clamping mechanism to limit movement of said adjustingscrew.
 9. An assembling method for a plastic-lens-forming casting moldcharacterized by comprising the step of fitting and temporarily fixing apair of molds in two open ends of a casting gasket integrally having apositioning projection projecting from an inner surface of the castinggasket such that lens-forming optical surfaces of the pair of molds comeinside, the step of clamping the casting gasket by a pair of clampingmeans from an axial direction, the first mold push-in step of pushingone of the pair of molds into the gasket by first push-in means to urgethe mold against the projection, and the second mold push-in step ofpushing the other mold into the gasket by second push-in means for apredetermined amount.
 10. An assembling method for aplastic-lens-forming casting mold according to claim 9, characterized inthat the second mold push-in step includes the step of pressing aperipheral portion of a surface of the other mold which is opposite to alens-forming optical surface by using, as the second push-in means, aplurality of pins which are biased in enlarging directions.
 11. Anassembling method for a plastic-lens-forming casting mold according toclaim 10, characterized in that the step of pressing the peripheralportion of the surface of the other mold which is opposite to thelens-forming optical surface includes the step of providing theplurality of pins such that heights thereof are adjustable individuallyand independently of each other.
 12. An assembling method for aplastic-lens-forming casting mold according to claim 9, characterized inthat the second mold push-in step includes the step of pressing a flatsurface which is formed on an outer peripheral portion of a concavesurface of the other mold.
 13. An assembling method for aplastic-lens-forming casting mold according to claim 9, characterized byfurther comprising the step of setting a push-moving amount of thesecond push-in means for the other mold to match a type of a lens. 14.An assembling device for a plastic-lens-forming casting mold accordingto claim 1, characterized in that said gasket clamping mechanismincludes first and second clamping means which clamp said casting gasketfrom an axial direction thereof by being urged against each open endface of said casting gasket.
 15. A molded product formed by anassembling device for a plastic-lens-forming casting mold, saidassembling device comprising a gasket clamping mechanism which clampseach end face of a casting gasket from an axial direction thereof, afirst mold push-in mechanism which pushes one mold fitted in one openend of said casting gasket into said casting gasket, and a second moldpush-in mechanism which pushes the other mold fitted in the other openend of said casting gasket into said casting gasket to oppose said onemold at a predetermined gap.
 16. A molded product formed by anassembling method for a plastic-lens-forming casting mold, theassembling method comprising